EXPERIMENT NO.

1
Object: - Study of general requirement of machine tool design.
Introduction: - Any machine should satisfy the following requirements.
1. High productivity
2. Ability to provide the required accuracy of shape and size and also necessary surface
finish
3. Simplicity of design
4. Safety and convenience of control
5. Good appearance
6. Low cost of manufacturing and operation

1. Productivity: - Productivity of a metal cutting machine tool is given by the expression

Q= (1/tc+tn0).n
tc = machine time
tn0 = non-productivity time that include job handling time.
a. Cutting down machining time: - This is possible if high cutting speeds and feed rates
are available on the machine tool in accordance with the latest development in cutting
tool material and design.
b. Machining with more than one tool simultaneously: - This principle employed in
multiple-spindle lathes, drilling machine etc.
c. Improving the reliability of the machine tool to avoid break down and adopt proper
maintenance policy to prevent unscheduled stoppages and delays.

2. Accuracy: - The accuracy of a machine tool depends upon its geometrical and kinematic
accuracy and its ability to retain this accuracy during operation. Accordingly the ability of a
machine tool to consistency machine parts with a specified accuracy with in permissible
tolerance limits can be improved by the following method.
a. Improving the geometrical accuracy of the machine tool: This is mainly determined by
the accuracy of guideways, power screw etc.
b. Improving the kinematic accuracy of the machine tool: This is determined the
relationship between velocities of two or more forming motion and it depends upon the length
of kinematic accuracy of machine tool can be improved.
c. Increasing the static and dynamic stiffness of machine tool structure. The greater in the static
stiffness of the machine tool structure the smaller will be its deformation due to cutting forces
and will be the accuracy of machining.
d. Providing accurate devices for measuring distance of travel.
e. Arranging the machine tools units in such a manner that the thermal deformation during the
machining operation result in the least possible change in the relative position between the tool
and the workpiece.

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3. Simplicity of design: - Simplicity of design of machine tool determines the ease of its
manufacture and operation. The design of machine tool can be simplified by using standard
parts and sub assembly as far as possible. The complexity of design of a machine tool depends
to a large extend upon the degree of its university. Thus a general purpose machine tool is a
rule more complex than a special purpose machine tool design doing similar operation.

4. Safety and convenience of control: - A machine tool cannot be deemed fit for use
unless it machine tools the requirement of safety and convenience of operation.
a. Shielding the rotating and moving parts of the machine tool with hoods.
b. Protecting the worker from chips, abrasive dust and coolant by means of screws shield etc.
c. Providing reliable clamping for the tool and workpiece.
d. Providing reliable earthing of the machine, providing device for safe handling of heavy
workpiece.

5. Appearance:- Good appearance of the machine tool influence the mood of the worker
favourably and thus facilities better operations it is generally conceded that a machine tool that
is simple in design and safe in operation and also good in appearance although factors, such as
external finish colour.
Nowadays, painting of machines in different colours according to the production purpose is
becoming popular.

6. Cost of manufacturing and operation: - The cost of manufacturing a machine tool

is determined by the complexity of its design. Therefore factors that help in simplifying the
machine tool design also contribute towards lowering its manufacturing cost.
The cost can also be brought down by reducing the amount of metal required in manufacturing
the machine tool. This is achieved by using stronger materials and more precise design
calculation pertaining to the strength and rigidly of parts to keep the safety margins as low as
possible.

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EXPERIMENT NO.2

Object: - Study of working and auxiliary motion of machine tool.

Introduction: - Obtaining the required shape on the workpiece, it is necessary that the
cutting edge of the cutting tool should move in a particular manner with respect to the
workpiece the relative movement between the workpiece and cutting edge can be obtained
either by the motion of the workpiece the cutting tool or by a combination of the motion of the
workpiece and cutting tool.
These motion which are essential are working to impart the required shape to the workpiece
are known as working motion. Working motions are further classified into two categories:
1. Drive motion or primary cutting motion
2. Feed motion

Working motion in machine tools generally of two types:

1. Rotary
2. Translatory

Fig: lathe fig: drilling

Fig: shaping fig: grinding

1 .For lathes and boring machines
Drive motion: Rotary motion of workpiece
Feed motion: Translatory motion of cutting tool in the axial or radial direction
2 .For drilling machines
Drive motion: Rotary motion of workpiece

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Feed motion: Translatory motion of drill

3 .For milling machines
Drive motion: Rotary motion of the cutter
Drive motion: Translatory motion of workpiece
4 .For shaping, planning and slotting machines
Drive motion: Reciprocating motion of cutting tool
Feed motion: Intermitted translatory motion of the workpiece
5 .For grinding machines
Drive motion: Rotary motion of grinding wheel
Feed motion: Rotary as well as translatory of the workpiece
Besides the working motion a machine tool also has provision for auxiliary motions.
In machine tool, the working motions are powered by sources of energy. The auxiliary motion
may be carried out manually or may also be power operated depending upon the degree of
automation of the machine tool. In general purpose machine tools, most of the auxiliary
motions are executed manually.

Parameters defining working motions of a machine tool

The working motions of the machine tool are numerically defined by their velocity, the velocity
of the primary cutting motion or drive motion is known as cutting speed while the velocity of
feed motion is known feed.
The cutting speed is denoted by v and measured in the units m/min. Feed is denoted bys
and measured in the following units.
1. mm/rev. in machine tool with rotary drive motion e.g. lathes, boring machine etc.
2. mm/tooth, in machine tool using multiple-tooth cutters e.g. milling machines.
3. mm/stroke, in machine tools with reciprocating drive motion e.g. shaping and planning
machine.
4. mm/min, in machine tools which have a separate power source for feed machines.
In machine tools with rotary primary cutting motion, the cutting speed is determined by the
relationship

v = 1000 m/min

d= diameter of workpiece or cutter

n= revolution per minute (rpm) of the workpiece or cutter
In machine tools with reciprocating primary cutting motion, the cutting speed is determined by

u = 1000Tc m/min

L= length of stroke mm

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Tc = time of cutting stroke min

If the time of the idle stroke in minutes is denoted by Ti, the number of strokes per minute can
be determined as
1
n = Tc +Ti

Generally, the time of idle stroke Ti, is less than the time of cutting stroke, if the ratio Tc/Ti is
denoted by K, the expression for number of strokes per minute may be written as
1
n= = (1+)
(1+ )

Now combining equations the relationship between cutting speed and number of strokes per
minute may be written as follows
(+1)
v=
1000

The feed per revolution and feed per stroke are related to the feed per minute by the relationship
Sm = s.n
Where, Sm = feed per minute
s = feed per revolution
n = number of revolution
The feed per tooth in multiple tooth cutter is related to the feed per revolutions as follows:
S = Sz.z
Where, S = feed per revolution
Sz = feed per tooth of cutter
z = number of tooth on the cutter
The matching time of any operation can be determined from the following basic expression

Tm = Sm min

Where, Tm = matching time, min

l = length of machined surface, mm
Sm = feed per minute

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Experiment No.-3
Objective: Design criterion for machine tool structure, Static & dynamic stiffness.

Introduction:- Machine tool consists of machine tool structure, bed, column, housings. These
are the base of machine tool on which the guideways, spindle, carriage, etc. are mounted. These
elements must able to withstand at higher permissible load. These elements are discussed in detail
in the following section.
Objectives is to understand
Functions of machine tool structure and the design criteria for selection of material for
sideways,
The design of bed,
The design of column, and
The design of housing.

FUNCTIONS OF MACHINE TOOL STRUCTURE:

Machine tool structure consists of bed, base, columns, box type housings, overarms,
carriages, tables etc.
The structures are divided into three categories according to their functions :

Category 1 An element, upon which various subassemblies are mounted, falls under this
category. Example: bed and base.

Category 2 Elements consist of box type housings in which individual parts are assembled
fall under this category. Example: Speed box housing, spindle head, etc.

Category 3 Elements consist of parts that are used for supporting and moving the workpiece
and cutting tool fall under this category. Example: Table, carriage, knee, tailstock etc.

Machine tool structure must satisfy the following requirement :

(a) The initial geometrical accuracy of the structure should be maintained for the whole life
of the machine tool.
(b) All mating surfaces of the structure should be machined with a high degree of accuracy to
provide the desired geometrical accuracy.
(c) The shape and size of structure should not only provide safe operation and maintenance of
the machine tool but also ensure that working stresses and deformation should not exceed
specific limits.
(d) The selection of material and high static and dynamic stiffness are the fundamental
requirement to fulfill above-mentioned requirement.

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DESIGN CRITERIA FOR MACHINE TOOL STRUCTURE:

The simple machine tool bed with two-side wall is represented as a simply supported beam. Figure
depicts a simply supported beam. Point load F acts at its center. The maximum normal stress acting
on the beam is given by

Figure : Simply Supported Beam

where Bmax = Maximum bending moment = FL/4 ,

In = Moment of inertia of the beam section about the neutral axis=bh3/12

On substituting these values in Eq. nmax changes to

The permissible normal stress under tension for the beam material is given by

Or minimum volume of material (Vmin) required to make sure that beam has sufficient strength is
given by

The maximum deflection of simply supported beam is given by the following expression :

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Where E is young modulus of beam material.

If the deflection of the beam dper is not to exceed a permissible value, then

Where Vmin = minimum volume of metal required to make sure that deflection of the beam under
load does not exceed the permissible value.

The condition of optimum design is given by

Hence Eq. indicates that for every structure, there exists an optimum ratio l/h and the ratio
l/h depends upon :
(a) Operation constraint i.e. dper.
(b) The material of the structure i.e. E and per.

Materials for Machine Tool Structure

The commonly used material for machine tool structures are cast iron and steel. Earlier cast
iron structures were widely used but due to advances in welding technology, welded steels
are widely used now days.
The selection of material for machine tool structure depends upon following factors:

Material properties
a) Cast iron has higher damping properties than steel. Welded steel also shows good
damping properties.
b) Cast iron has better sliding properties.
c) Steel has higher strength under static and dynamic loading.
d) The unit rigidity of steel under tensile, torsional and bending loads is higher than cast
iron.

Manufacturing Problems
Welded structures of steel have much thinner wall thickness as compared to cast structure.
Walls of different thickness can be welded more easily than casting it. Machining allowances
for cast structures are generally greater than for weld steel structures. Machining allowance is

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necessary in casting to remove defects such as inclusions, scales, etc. Welded structure can be
easily repaired as compared to cast structure.
Economy
The selection of material for structure will also depend upon its cost. The weight of steel is
lesser and but actual metal consumption is higher than that of cast iron. Hence in such cases
the cost increases. Holes are obtained with the help of core in the casting structure but holes
are made in welded steel structure by machining. These will not only increase the material
cost but also increases labour cost. Cost of patterns, welding fixtures, and cost of machining
are considered while selecting material for structure.

On considering above factors, the cast iron and steel may be used for following application:
a) Cast iron should be used for complex structure subjected to normal loading which are
to be produced in large number.
b) Steel should be used for simple and heavy loaded structures which are to be produced
in small number.
c) Combined welded steel and cast iron should be used where steel structure is
economically suitable. Example: Cast bearing housings that are welded into the feed
box.

Machine Dynamics:
The machining and machine dynamics within the machine system should be well understood,
optimized and controlled, because they have the following direct effects:
They may degrade machining accuracy and the machined surface texture and
integrity.
They may lead to chatter and unstable cutting conditions.
They may cause accelerated tool wear and breakage.
They may result in accelerated machine tool wear and damage to the machine and
part.
They may create unpleasant noises and sounds on the shopfloor because of the chatter
and vibrations.

Loop Stiffness within the Machine-tool-work piece System:

Stiffness: stiffness normally can be defined as the capability of the structure to resist
deformation or to hold a position under the applied loads. Static stiffness in machine tools
refers to the performance of structures under the static or quasi-static loads. Static loads in
machine tools normally come from gravity and cutting force etc. apart from the static loads,
machine tools are subjected to constantly changing dynamic forces and the machine tool
structure will deform according to the amplitude and frequency of the dynamic excitation
loads, which is termed dynamic stiffness

Machine-tool-workpiece Loop Concept

From the machining point of view, the main function of a machine tool is to accurately and
repeatedly control the contact point between the cutting tool and the uncut material - the
machining interface. Figure 2.1 shows a typical machine tool-work piece loop. The
machine-tool-work piece loop is a sophisticated system which includes the cutting tool, the
tool holder, the slideways and stages used to move the tool and/or the workpiece, the spindle
holding the workpiece or the tool, the chuck/collet, and fixtures, etc. If the machine tool is

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being taken as a dynamic loop, the internal and external vibrations, and machining processes
should be also integrated into this loop as shown in Figure 2.2.

Stiffness can normally be defined as the capability of the structure to resist deformation or
hold position under the applied loads. Whilst the stiffness of individual components such as
spindle and slideway is important, it is the loop stiffness in the machine-tool system that
determines machining performance and dimensional and forming accuracy of the surface
being machined, i.e., the relative position between the workpiece and the cutting tool directly
contributes to the precision of a machine tool and correspondingly leads to the machining
errors.

Fig. A typical machine tool loop

Fig. The machine-tool-workpiece loop taking account of machining processes and dynamic
effects

Static Loop Stiffness

Static loop stiffness in machine tools refers to the performance of the whole machine-tool
loop under the static or quasi-static loads which normally come from gravity and cutting
forces in machine tools.
A simplified analogous approach to obtaining the static loop stiffness is to regard the machine
tool individual elements as a number of springs connected to each other in series or in
parallel, so that the static loop stiffness can be derived based on the stiffness of each
individual element:

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Typically, a well designed machine-tool-workpiece system may have a static loop stiffness of
around 50N/m; a figure of 500 N/m is well desired for heavy cutting machine tools in
particular. While a loop stiffness of about 10N/m seems not rigid enough, it is quite
common in precision machines. Static loop stiffness can be predicted at the early design stage
by analytical or numerical methods and thus design optimization and improvement are
essential; also, a continuous process because of the increasing demands from the various
applications.

Dynamic Loop Stiffness and Deformation

Apart from the static loads, machine tools are subjected to constantly changing dynamic
forces and the machine tool structure will deform according to the amplitude and frequency
of the dynamic excitation loads, which is termed dynamic stiffness. Dynamic stiffness of the
system can be measured using an excitation load with a frequency equal to the damped
natural frequency of the structure.
Following Equations provide a rough approximation of dynamic stiffness kdyn and
deformation xdyn:

where F is the dynamic load applied to the machine tool, kstatic is the static stiffness of the
machine tool, and Q is the amplification factor which can be calculated from:

where M and c is the mass and damping:

Therefore,

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In order to accurately predict and calculate dynamic loop stiffness or the behaviour of a
whole machine-tool system, a dynamic model including all elements in the machine-tool loop
needs to be developed. The finite element method has been widely used to establish the
machine tool dynamics model and provide the solution with reasonable accuracy.

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EXPERIMENT NO.4

Object: Draw a neat schematic diagram of herring bone gear and explain

Introduction
A herringbone gear, a specific type of double helical gear, is a special type of gear that is a side
to side (not face to face) combination of two helical gears of opposite hands. From the top,
each helical groove of this gear looks like the letter V, and many together form a herring bone
pattern (resembling the bones of a fish such as a herring). Unlike helical gears, herringbone
gears do not produce an additional axial load.
Like helical gears, they have the advantage of transferring power smoothly because more than
two teeth will be in mesh at any moment in time. Their advantage over the helical gears is that
the side-thrust of one half is balanced by that of the other half. This means that herringbone
gears can be used in torque gearboxes without requiring a substantial thrust bearing. Because
of this herringbone gears were an important step in the introduction of the steam turbine to
marine propulsion.
Precision herringbone gears are more difficult to manufacture than equivalent spur or helical
gears and consequently are more expensive. They are used in heavy machinery.
Where the oppositely angled teeth meet in the middle of a herringbone gear, the alignment may
be such that tooth tip meets tooth tip, or the alignment may be staggered, so that tooth tip meets
tooth trough. The latter alignment is the unique defining characteristic of a Wuest type
herringbone gear, named after its inventor.

Benefits
Since a herringbone gear is non-linear in the teeth the gears won't slip out from grabbing one
another if the axle or another force moves the gears up and down. This is also a benefit with
machinery that needs very straight movement, because a herringbone gear is designed to 'self
center' and is much less likely to skip a tooth or fall out of place. With some gears sets that use
herringbone gears; an axle can be lost and the gear will stay in place, a herringbone planetary
gear system.

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Manufacture
A disadvantage of the herringbone gear is that it cannot be cut by simple gear
hobbing machines, as the cutter would run into the other half of the gear. Solutions to this have
included assembling small gears by stacking two helical gears together, cutting the gears with
a central groove to provide clearance, and (particularly in the early days) by casting the gears
to an accurate pattern and without further machining. With the older method of fabrication,
herringbone gears had a central channel separating the two oppositely-angled courses of teeth.
This was necessary to permit the shaving tool to run out of the groove. The development of the
Sykes gear shaper made it possible to have continuous teeth with no central gap. Sunderland,
also in England, also produced a herringbone cutting machine. The Sykes uses cylindrical
guides and round cutters; the Sunderland uses straight guides and rack-type cutters. The W. E.
Sykes Co. dissolved in 198384. Since then it has been common practice to obtain an older
machine and rebuild it if necessary to create this unique type of gear. Recently, the Bourn and
Koch Company has developed a CNC-controlled derivation of the W. E. Sykes design called
the HDS1600-300. This machine, like the Sykes gear shaper, has the ability to generate a true
apex without the need for a clearance groove cut around the gear. This allows the gears to be
used in positive displacement pumping applications, as well as power transmission. Helical
gears with low weight, accuracy and strength may be 3D printed.
The herring bone gear is essentially a pair of helical gear in which the helix angel is oppositely
direct.

In a gear transmission, the rpm of the drives shapes is determined as

1
2 = 1 .
2

Where 1 =rpm of the driven shaft

2 =rpm of the driving shaft

1 =no. of teeth of the drawing gear

2 =no. of teeth of the driven gear

The ratio 1 / 2 is known as the transmission ratio of the gear driven and is constant for a
particular gear pair.

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EXPERIMENT NO.5

Object Study of different mechanism used for transforming rotary motion into
translator Slider crank mechanism
1. Cam mechanism
2. Rack and pinion mechanism
3. Nut and screw mechanism

Theory These elementary transmissions are employed in feed mechanism of most of the
machine tools and also in the drives of machine tools have a reciprocating primary cutting
motion.
The Important elementary transmissions that are used in machine tools for transforming rotary
motion into translatory motion are:

1. Slider crank mechanism

Fig: Slider crank mechanism

The machine consists of a crank, connecting rod and slider. The forward and reverse stroke
each take place during a revolution of crank therefore the need speed of forward and reverse
speed in slider crank mechanism since metal removal occur during one stroke. It is desirable
from the point of view of productivity to have a higher speed of the other stroke. Due to this
property of slider crank mechanism is used only in an appreciable increase of productivity e.g.
in the driving of primary cutting motion of gear shaping machine the length of stroke may be
change by adjusting the crank radius and is equal to
L = 2R, where R is the crank radius

2. Crank and Rocker mechanism

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The crank and rocker mechanism consist of a rotating crank which makes the rocker arm
oscillate by means of a block sliding along the groove in the rocker arm the clockwise rotation.
The forward cutting stroke takes place during the clockwise rotation of the crank through angle
and the reverse stroke during rotation of the crank through angle since > and the
crank rotation with uniform speed. The ideal stroke completes transfer than the cutting stroke.
The length of stroke can be varied by adjusting the crank radius with a decrease in crank radius.
The ratio of angle decrease and the speed of cutting and reverse stroke tend to become
equal preferred in machine tool with large stroke (up to 1000 mm) where it can be effectively
employed e.g. in drive of the primary cutting motion of shaping and slotting machine.
Length of stoke can be calculated,

L = 2() R mm

L = length of rocker
e = offset distance
R = radius of crank

3. CAM Mechanism

The cam mechanism consists of a cam and a follower the cam mechanism provides the desired
translatory motion is a suitable profile is selected. The profile may be provided.
a. On the periphery of a disc-disc type mechanism.
b. On the face of a disc-face type cam mechanism.
c. On a cylindrical surface-drum type cam mechanism.
The main advantage of cam mechanical is that the velocity of the operative element is
independent of the design of driving mechanism and is controlled by the cam profile.
In a disc type cam if the radius change from R1 to R2 along an spiral while the cam rotate
through angle , the velocity of the follower can be determined from the expression.
21
v= . 360. m/min
1000

n = rpm of the cam

R1,R2 = radius mm
In face or drum type cam mechanism the speed of the follower depends upon the steepness of
the grove consider for instance. The profile development of drum cam segment a deplict the

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steep rise of follower corresponding to the rapid advanced segment deplict the slow rise
corresponding to the steep full corresponding to the rapid withdraw of cutting tool.
..
v= . m/min
1000

h = rise during the working stroke

b = length of the working stroke
D = diameter of the drum in mm
s = rpm of drum

4 .Nut and Screw transmission

Schematic diagram of anti-friction nut and screw transmission

A nut and screw mechanism is schematically depicted the screw and nut have a trapezoidal
thread. The direction movement can reverse by reversing rotation of the screw. The nut and
screw transmission is compact but has a high load carrying case capacity its other advantage
are simplicity case of manufacturing the possibility of achieving slow and uniform movement
of the operating member.
The speed of operating member can be found from relationship
Sm = t.k.n mm/min
t = pitch of thread
k = number of thread
n = rpm of the screw

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5. Rack and pinion transmission

Fig: rack and pinion transmission

When the rotating gear meshes with a stationary rack, the centre of the gear moves in
straight line on the other hand if the gear axis is stationary then the rack executes
translatory motion. The direction of motion can be reversed by reversing the rotation of the
pinion.
Sm = .z.n mm/min
Sm = feed per minute of the operative member
m = module of the pinion
z = number of teeth of the pinion
n = rpm of the pinion
Rack and pinion transmission is the simplest and cheapest among all types of transmission used
in reversible driven. It also has high efficiency and provides a large transmission ratio which
makes it possible to use it in the feed as well as main drive mode.

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EXPERIMENT NO.6

Objective: Draw the diagram of following mechanism.

1. Ratchet gear mechanisms
2. Geneva mechanism
3. Reversing mechanism
4. Differential mechanism

Introduction
Devices for intermittent motion
In some machine tools, it is required that the relative position between the cutting tool and
workpiece should change periodically.
a .Machine tools with a reciprocating primary cutting motion e.g. shaping machine in which
the workpiece must be intermittently upon completion of one full stroke of the cutting tool.
b .machine tools with reciprocating feed motion.

1. Ratchet gear mechanism

The Ratchet gear mechanism is generally consists of a pawl mounted on an oscillating pin.
During each oscillation in the anticlockwise direction, the pawl turns the ratchet wheel through
a particular angle. During the clockwise oscillating in the opposite direction, the pawl simply
slides over the ratchet teeth and the latter remain stationary. The ratchet wheel is linked to the
machine tool table through a nut and screw transmission. Therefore the periodic rotation of the
ratchet wheel is transformed into the intermittent translator motion of the table for a particular
nut and screw pair of some constant transmission ratio. The feed of the table during each
oscillation depends upon the swing of the oscillating pawl. The rotation of the ratchet wheel in
one stroke of the pawl should not exceed 45. The ratchet gear mechanism is most suitable in
case when the periodic displacement must be completed in a short time.

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2. Geneva mechanism -

Fig: Geneva mechanism

Geneva mechanism consists of a driving disc which rotates continuously and a wheel a wheel
with four radial slots. The arc on the driving disc and wheel provide a locking effect against
rotation of the slotted wheel e.g. position of the wheel cannot rotate. As the disc continuous to
rotate, point A of the disc comes out of contact with the arc and immediately thereafter pin p
mounted at the end of the driving arm enters the radial slot.
The wheel now begins to rotate when it has turned an angle 90 the pin comes out of the radial
slot and immediately thereafter point B comes in contact with the next arc of the wheel
preventing its further rotation. In the Geneva mechanism the angle of rotation of the wheel
cannot varied.
Application
(i) Mainly used in torrents.
(ii) Single spindle automatic machine for indexing cutting tools.
(iii) Multi spindle automatic machines for indexing spindle through a constant angle.

3. Reversing mechanism

These mechanisms are used for changing the direction of motion of the operative member.
Reversing is accomplished generally through spur and helical gears. A few reversing
arrangements using spur and helical gear. In this arrangement the gear on the driving shaft are
mounted rigidly. While the idle gear and gears on the driven shaft are mounted freely. The jaw
clutch is mounted on a key, rotation may be transmitted to the driven shaft either through gear

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(A/B), (B/C) or through D/E depending upon whether the jaw clutch is shifted to the left to
mesh with gear C or to the right to mesh with gear E.
In the second arrangement, the gears on the driving shaft are again rigidly mounted and the idle
gear is free. On the driven shaft a double cluster gear is mounted on a spline. By sliding the
cluster gear transmission to the driven shaft may again be achieved either through gear (A/B),
(B/C) or through gear pair D/E.
In the third arrangement gear A on the driving shaft and gear D on the driven shaft are both
rigidly mounted. A quadrant with constantly meshing gear B and C can be swivelling about the
axis of the driven shaft. By swivelling the quadrant with the help of a lever transmission to the
driven shaft may be achieved through (A/C), (C/D) or through (A/B) (B/C)(C/D).

4. Differential mechanism

Differential mechanisms are used for summing two motions in machine tools in which
operative member gets input from two separate kinematics trains. They are generally employed
in thread and gear cutting machines where the machined surface is obtained as a result of the
summation of two or more forming motions.
A simple differential mechanism using spur or helical gears is shown. The mechanism is
essentially a planetary gear mechanism consisting of sun gear A, planetary gear B and arm C.
The planetary gear is mounted on the arm which can rotate about axis of gear A. suppose gear
A makes nA and arm C, nC revolutions per minute in the clockwise direction. The relative
motion between the elements of the mechanism will remain unaffected if the whole mechanism
is rotated in the anticlockwise direction with nC revolution per minute.
The transmission ratio of the mechanism may be written as
nA nC/nB nC =- zB/zA
Where zA and zB are the number of teeth of gear A and B, respectively. The above expression
may be written as follows.
nB = nC(1+zA/zB) nA(zA/zB)
Differential mechanisms are using a double cluster planetary gear. The mechanism consists of
gear A, cluster gear block B-B mounted on arm C and gear D. If nA, nB, nC are the rpms of
gear A, arm C and gear D, respectively then the transmission ratio of the kinematic train
between gear A and D may be expressed as
nD nC/nA nC = zA/zB . zB/zD

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The mechanism consist of bevel gears A and D and planetary level gears B and C. Planetary
gear can be rotated about the common axes of gear A and D.
1. By means of a ring gear this differential is used in automobiles.
2. By means of a T- shaped shaft this differential is used in machine tools.
3. if gear A,B and D make nA, nB, nD revolutions per minute, respectively, then the transmission
ratio of the kinematic train between gear A and D can be written as
nA nB/nD nB = - zA/zB . zB/zD
Where zA, zB, zD are the number of teeth of gears A, B and D respectively.

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EXPERIMENT NO.7
Object: Which Speed Series are used in machine tool gear box. Justify the insure
with process reason.
Gear boxes
-Ap & Gp for steeping speeds of gears.
-Structural Formula & Structural diagrams.

Gear boxes
Machine tool characterized by their large number of spindle speeds and feeds of cape with
the requirements of machine parts of different materials and dimension using different types
of cutting tool materials and geometries. The cutting speed is determined on the bases of the
cutting ability of the tool used. Surfaces finish required and economical consideration.

Speed Range for different Machine Tools

Machine Range
Numerically Controlled lathes 250
Boring 100
Milling 50
Drilling 10
Surface Finish 4

Stepping of Speed According to Arithmetic Progression (AP)-

Let 1 ,2 ,.., be arranged according to arithmetic progression.
Then 1 -2 = 3 -2 = Constant
The saw tooth diagram in such a case is show in fig. Accordingly, for an economical cutting
Speed 0 , the lowest speed 1 is not constant, it decrees with increasing dia. Therefore , the
arithmetic progression does not permit economical machine at large diameter ranges. The main
disadvantage of such an arrangement is that the percentage drop from step to step decrees as
the speed increase. Thus the speed are not evenly distribution and more concentrated and
closely stepped , in the small diameter range than in the large one. Stepping speeds according
to arithmetic progression are used in Norton gear box with a sliding key when the number of
shaft is only two.

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Speed stepping according to arithmetic progression

Stepping of Speed According to Geometric Progression (GP)-

As show in Figure, the percentage drop from one step to the other is constant, and the absolute
loss of economically expedient cutting speed v is constant all over the whole diagram range.
The relative loss of cutting speed /0 is also constant Geometric progression. Therefore,
allow machining to take place between limits 0 and independent of the WP diagram, where
0 is the economical cutting speed and is the allowable minimum cutting speed. Now
suppose that 1 ,2 ,.., are the spindle speeds. According to the geometric progression
2 2
= =
1 1

Where is the progression ratio. The spindle speed can be expressed in term of the minimal
speed n1 and progression ratio

n1 n2 n3 n4 nz
n1 n1 n1 2 n1 3 n1 z-1

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Hence, the maximum spindle speed nz is given by

= 1 1
Where z is the number of spindle speed, therefore

1 2 1
= =
1

log
= +1
log
ISO Standard values of progression ratio
(1.06, 1.12, 1.26, 1.4, 1.6, 1.78, 2.0)
Justify ensuring with reason
1. Transmission ratio imax =2, imax =1/4, ig = imax/ imin=8
2. Minimum total shaft size

The torque transmitted by a shaft is given by

1


1/3

From the strength consideration: ( 1 ) = ( 2 )
2 1

3. For last radial dimensions of gear box imax* imin = 1

4. No of gears on last shaft should be minimum.
5. No of gears on any shaft should be limited to 3

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EXPERIMENT NO.8
Object: Design Procedure of machine tool gear box design
Gear Box
Machine tools are characterized by their large number of spindle speeds and feeds to cope with
the requirements of machining parts of different materials and dimensions using different types
of cutting tool materials and geometries. The cutting speed is determined on the bases of the
cutting ability of the tool used, surface finish required, and economical considerations. A wide
variety of gearboxes utilize sliding gears or friction or jaw coupling. The selection of a
particular mechanism depends on the purpose of the machine tool, the frequency of speed
change, and the duration of the working movement. The advantage of a sliding gear
transmission is that it is capable of transmitting higher torque and is small in radial dimensions.
Among the disadvantages of these gearboxes is the impossibility of changing speeds during
running. Clutch-type gearboxes require small axial displacement needed for speed changing,
less engagement force compared with sliding gear mechanisms, and therefore can employ
helical gears. The extreme spindle speeds of a machine tool main gearbox nmax and nmin can be
determined by
1000
=

1000
=

where Vmax = maximum cutting speed (m/min) used for machining the most soft and
machinable material with a cutting tool of the best cutting property Vmin = minimum cutting
speed (m/min) used for machining the hardest material using a cutting tool of the lowest cutting
property or the necessary speed for thread cutting dmax, dmin = maximum and minimum
diameters (mm) of WP to be machined
The speed range Rn becomes

= = . =

Rv = cutting speed range Rd = diameter range In case of machine tools having rectilinear main
motion (planers and shapers), the speed range Rn is dependent only on Rv. For other machine
tools, Rn is a function of Rv and Rd, large cutting speeds and diameter ranges are required.
Generally, when selecting a machine tool, the speed range Rn is increased by 25% for future
developments in the cutting tool materials.

Design procedure for gear box

1. Determine the maximum and minimum speed of the output shaft. Then calculate the
number of steps or speeds reduction stages for this range. This depends on the
application as well as space optimization. Higher reduction stages require more space
because of more number of gears and shafts requirements.

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2. Select types of speed reduction or gear box based on the power transmission
requirements, gear ratio, and position of axis space available for speed reducer.
Also make sure that for low gear ratio requires single speed reduction. Select worm
gear for silent operation and level gear for interesting axis.

3. Determine the progression ratio which is ratio maximum speed and minimum speed of
output shaft of the gear box the nearest progression ratio should be a standard one and
it taken either from R20 or R40 series.

4. Draw the structural diagram and kinematic arrangement indicating various arrangement
possibilities during speed reduction or increment.

5. Select materials for gears so that gear should sustain the operating condition and
operating load. Normally cast iron is chosen for housing and cast steel or other all can
be selected as per the load requirements.

6. Note down the maximum power output in horse power (H.P) or transmission power
and revolution per minute of shaft i.e. rpm of each shaft.

7. Determine the centre distance between the driven and driver shaft based on the surface
compressive stress.

8. Determine the module of gear by beam strength as well as fix the number of teeth
required.

9. Calculate the diameter of the shaft by torque requirements and bending moment
consideration.

10. Calculate the key size, shape or type of transmission key for each gears.

11. Select appropriate fit and tolerance for matting parts like shaft and gear.

12. Select bearing types or the loading and operating conditions. Also make sure to include
consideration of maximum speed and expected life of gear and gear box.

13. Make the shaft stepped or provide collar to prevent axial displacement of bearing and
gear.

14. Provide suitable clearance between gear and walls of the housing of gear box and based
on this considerations design the casing/housing of gear box.

15. Complete the design of casing in drawing by providing fires if necessary to have
increased heat transfer by convection and conduction. Put inspection hole/man hole as
well as drain hole to drain lubricating oil. Also provide oil level indicator to have proper

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amount of oil during operation, if not out, this will lead to failure of gear and shaft due
to over heating or due to friction failure.

16. Draw neat a clean working drawing in suitable software like auto cad, pro engineer etc.
indicating required details during manufacturing or assembly.

17. One can also perform finite element analysis of the complete gear box after it
completely designed.

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EXPERIMENT NO.9
Object: Description of stick-slip and sliding friction in machine tool design.
Stick-slip Friction
Stick-slip can be described as surface alternate between sticking to each other and sliding
over each other with a corresponding change in the force of friction coefficient between two
surfaces is larger than the reduction of the friction to the kinetic friction can cause a sudden
jump in the velocity of the movements. The attached picture shows symbolically an example
of stick-slip.
V is the drive system, R is the elasticity in the system and M is the load i.e. lying on floor and
is being pushed horizontally. When the drive is started, the spring R is loaded and its pushing
force against load M increases until the static friction coefficient between load M and floor is
not able to hold the load anymore. The load start sliding and the friction coefficient decreases
from its static value to its dynamic value. At this moment, the spring can give more power
and accelerate M.
During Ms movements, the force of the spring decreases, until it is insufficient to the
overcome the dynamic friction. From this point M de-accelerate to a stop. The drive system
however, continues and the spring is loaded again etc.

Fig.- Stick-Slip Phenomenon

Sliding (motion) Friction

Sliding is a type of friction motion between two surfaces in contact. This can be constructed
to rolling friction. Both types of motion may occur in bearing.
Friction may damage or wear the surface in contact. However, it can be reduced by lubrication.
The science and technology of friction, lubrication, and wear is known as tribology.

Sliding may occur between two objects of arbitrary shape, whereas rolling friction is the
friction force associated with the rotational movement of a somewhat dislike or other circular
object along the surface.

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In engg sliding friction occur in numerous types of sliding components such as journal bearing,
cams, linkage, and pistons in cylinders. Static friction is the friction required to move two
surfaces that are not in relative motion.

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EXPERIMENT NO.10
Object: Free body diagram of following machines:
(1) Lathe
(2) Drilling
(3) Shaping
(4) Milling

Introduction
Lathe
The lathe is a machine tool used principally for shaping articles of metal (and sometimes wood
or other materials) by causing the workpiece to be held and rotated by the lathe while a tool bit
is advanced into the work causing the cutting action. The basic lathe that was designed to cut
cylindrical metal stock has been developed further to produce screw threads, tapered work,
Drilled holes, knurled surfaces, and crankshafts. The typical lathe provides a variety of rotating
speeds and a means to manually and automatically move the cutting tool into the workpiece.
Machinists and maintenance shop personnel must be thoroughly familiar with the lathe and its
operations to accomplish the repair and fabrication of needed parts.

Types of lathe

Lathes can be divided into three types for easy identification: engine lathes, turret lathes, and
special purpose lathes. Small lathes can be bench mounted, are lightweight, and can be
transported in wheeled vehicles easily. The larger lathes are floor mounted and may require
special transportation if they must be moved. Field and maintenance shops generally use a lathe
that can be adapted to many operations and that is not too large to be moved from one work
site to another. The engine lathe is ideally suited for this purpose. A trained operator can
accomplish more machining jobs with the engine lathe than with any other machine tool. Turret
lathes and special purpose lathes are usually used in production or job shops for mass
production or specialized parts. While basic engine lathes are usually used for any type of lathe
work. Further reference to lathes in this chapter will be about the various engine lathes.

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Drilling Machine
A drilling machine comes in many shapes and sizes, from small hand-held power drills to bench
mounted and finally floor-mounted models. They can perform operations other than drilling,
such as counter sinking; counter boring, reaming, and tapping large or small holes. Because
the drilling machines can perform all of these operations, this chapter will also cover the types
of drill bits, took, and shop formulas for setting up each operation. Safety plays a critical part
in any operation involving power equipment. This chapter will cover procedures for servicing,
maintaining, and setting up the work, proper methods of selecting tools, and work holding
devices to get the job done safely without causing damage to the equipment, yourself, or
someone nearby. A drilling machine, called a drill press, is used to cut holes into or through
metal, wood, or other materials. Drilling machines use a drilling tool that has cutting edges at
its point. This cutting tool is held in the drill press by a chuck or Morse taper and is rotated and
fed into the work at variable speeds. Drilling machines may be used to perform other
operations. They can perform countersinking, boring, counter-boring, spot facing, reaming, and
tapping.

Drill press operators must know how to set up the work, set speed and feed, and provide for
coolant to get an acceptable finished product. The size or capacity of the drilling machine is
usually determined by the largest piece of stock that can be center-drilled. For instance, a 15-
inch drilling machine cans center-drill a 30-inch-diameter piece of stock. Other ways to
determine the size of the drill press are by the largest hole that can be drilled, the distance
between the spindle and column, and the vertical distance between the worktable and spindle.

All drilling machines have the following construction characteristics: a spindle, sleeve or quill,
column, head, worktable, and base.

1. The spindle holds the drill or cutting tools and revolves in a fixed position in a sleeve. In
most drilling machines, the spindle is vertical and the work is supported on a horizontal table.

2. The sleeve or quill assembly does not revolve but may slide in its bearing in a direction
parallel to its axis. When the sleeve carrying the spindle with a cutting tool is lowered, the
cutting tool is fed into the work: and when it is moved upward, the cutting tool is withdrawn
from the work. Feed pressure applied to the sleeve by hand or power causes the revolving drill
to cut its way into the work a few thousandths of an inch per revolution.

3. The column of most drill presses is circular and built rugged and solid. The column supports
the head and the sleeve or quill assembly.

4. The head of the drill press is composed of the sleeve, spindle, electric motor, and feed
mechanism. The head is bolted to the column.

5. The worktable is supported on an arm mounted to the column. The worktable can be adjusted
vertically to accommodate different heights of work. or it may be swung completely out of the
way. It may be tilted up to 90 in either direction, to allow for long pieces to be end or angled
drilled.

6. The base of the drilling machine supports the entire machine and when bolted to the floor,
provides for vibration-free operation and best machining accuracy.

7. The top of the base is similar to a worktable and maybe equipped with T-slots for mounting
work too large for the table.

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FBD of Drilling Machine

Shaping Machine
The main functions of shaping machines are to produce flat surfaces in different planes. The
cutting motion provided by the linear forward motion of the reciprocating tool and the
intermittent feed motion provided by the slow transverse motion of the job along with the bed
result in producing a flat surface by gradual removal of excess material layer by layer in the
form of chips. The vertical infeed is given either by descending the tool holder or raising the

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bed or both. Straight grooves of various curved sections are also made in shaping machines by
using specific form tools. The single point straight or form tool is clamped in the vertical slide
which is mounted at the front face of the reciprocating ram whereas the workpiece is directly
or indirectly through a vice is mounted on the bed.

Fig. Shapping Machine

Milling Machine
Milling is the process of machining flat, curved, or irregular surfaces by feeding the workpiece
against a rotating cutter containing a number of cutting edges. The milling machine consists
basically of a motor driven spindle, which mounts and revolves the milling cutter, and a
reciprocating adjustable worktable, which mounts and feeds the workpiece. Milling machines
are basically classified as vertical or horizontal. These machines are also classified as knee-
type, ram-type, manufacturing or bed type, and planer-type. Most milling machines have self-
contained electric drive motors, coolant systems, variable spindle speeds, and power-operated
table feeds. Free body diagram of the milling machine shown in figure below

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Fig. Milling Machine

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EXPERIMENT NO.11
Object: Application of slideways profiles and their combinations
Slideway Sketch Application
Profile and
Combinatio
n for Bads
Open V + Planning
Open V Machines

Closed V + Precision lathes

Closed V and turret lathes

Open flat + Surface-grinding

Open V machines

Closed flat + Genral-purpose

Closed V lathes & heavy
duty boring
machine

For vertical columns

Closed flat + Most
Closed flat Commonly used
for all types of
vertical columne

Closed flat + Knee types

Closed flat milling machine
small vertical
drilling machine
and traverses of
radial drilling
machine

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Closed flat + Same us above

heavy-closed
dovetail

For cross slides and compound rests

Closed Cross slides &
devotail compound rests

Closed flat + Cross slides of

Closed flat heavy duty
machine tools

For Rotary Blades

Flat Surface-grinding
machine and
small hobbing
machine

W Precission gear-
hobby machine

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EXPERIMENT NO.12
Object: Functions and types of Guide ways

Machine Tool Guide Ways

In 30 years in the machine tool business, Ive learned a lot about guide ways to share with end-
users and builders alike. Much like spindles, cast iron beds, and weldments, each type of guide
way has its place. Guide ways now give you the choices to run faster or cheaper, and yet the
debate over which guide way is best still rages.

In 1999, American Machinist described state-of-the-art linear, ball, and box ways. Some
machine builders who shared their views are no longer in business, and at least one who is
endorsed one design at the time, but has since switched camps. This isnt surprising given how
far way design has come.

The primary enhancement for linear systems is additional contact on the rail, whereas box ways
now sport a better mating surface between the box and hardened way and better oils for reduced
friction. Small machines are now split between linear ways and, when more rigidity for heavy
cutting or tool life is a priority, box ways. Though some large machines are built with linear
systems too, hydrostatic ways are far more popular for big applications.

Linear systems were once considered more cost efficient for production and assembly of
machine tools. However, in the case of a heavy or large linear system, the cost savings are
likely offset by expenses later on, leveling the playing field with box ways.

Ultimately, the choice of guide way depends on the end-users priorities. Are they after speed,
rigidity, tool life, acceleration, accuracy, torque, hard metal machining, or cost savings? A 20
HP 40-taper VMC could be built with linear or box ways to meet any cutting criteria. In the
marketplace, however, linear rules for machines of this size: almost 80% of the 40 taper VMCs
built worldwide are linear. For 40 HP to 60 HP HMCs, though, more builders are using box
ways or hybrid-designed ways to meet strict speed and rigidity requirements.

This debate has raged for at least 16 years and theres still no winner. End users are pushing
builders for more speed and better accuracy. These improvements, however, may come at the
cost of tool life and the quality of the finished part. In 1998, I lost an order for a large VMC to
cut Inconel knives for the steel industry. They bought a more expensive box-way VMC over
my linear system since they thought it would last longer, provide better tool life, and yield
better finished parts. Did they make the right choice? Its hard to tell, especially when
technology is changing at a breakneck pace, and the answer to, Which is best? is always, It
depends.

The Guideway is one of the important elements of machine tool. The main function of the
guideway is to make sure that the cutting tool or machine tool operative element moves along
predetermined path. The machine tool operative element carries workpiece along with it. The
motion is generally circular for boring mills, vertical lathe, etc. while it is straight line for lathe,
drilling, boring machines, etc.

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The basic function of guideways is to ensure that the machine tool operation element carrying
the workpiece or cutting tool moves along a predetermined path which is generally a straight
line as in lathe, drilling, boring machines etc. or circular as in vertical turret lathe and boring
mills. The major requirements that the guideways must satisfy are:

1) High accuracy and surface finish of guideways surface.

2) High accuracy of travel which is possible only when the deviation of the actual path of
travel of the operative element from the predetermined path is minimum.
3) Durability which depend upon the ability of guideways, to retain the initial accuracy of
manufacturing and travel.
4) Low value of frictional forces acting on the guideways surface to ensure less wear.
5) Minimum possible variation of the coefficient of friction.
6) High rigidity.
7) Good damping properties.

Surface of the guideways and operate element. Guideways can be classified as:

(a) Guideways with sliding friction

(b) Guideways with rolling friction

Guideways with Sliding Friction

The friction between the sliding surfaces is called as guideways with sliding friction. These
guideways are also called as slideways. The slideways are further classified according to the
lubrication at the interface of contacting surfaces. The friction between the sliding surfaces
may be dry, semi-liquid, and liquid. When the lubrication is absent in between contacting
surfaces, it is called as dry friction. Dry friction is rarely occurred in machine tools.
When two bodies slide with respect to each other having lubrication between them, the
sliding body tends to rise or float due to hydrodynamic action of the lubricant film. The
principle of slider is shown in Figure 1.

Figure1. Principle of a Slider

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The hydrodynamic force,

= (1)

Where C is constant and depends upon wedge angle , the geometry of sliding surfaces,
viscosity of the lubricant and parameter of lubricant film.

vs is sliding velocity.
W is weight of the sliding body.
The resultant normal force acting on sliding body,
R = Fh W
From Eq. (1), it is clear that the hydrodynamic force increases with increase in sliding velocity.
The sliding body rests on the stationary body when hydrodynamic force is less than the weight
of the sliding body. Here, there are semi-liquid type friction conditions and under these
conditions the two bodies are partially separated by the lubricant film and partially have metal
to metal contact. The resultant normal force on sliding body starts to act upwards and the body
floats as hydrodynamic force is greater than the sliding weight of the body. The sliding surfaces
are completely separated by the lubricant film and liquid friction occurs at their interface. The
slideways in which the sliding surfaces are separated by the permanent lubricant layer are
known as hydrodynamic slideways. This permanent lubrication layer is due to hydrodynamic
action. A permanent lubricant layer between the sliding surfaces can be obtained by pumping
the liquid into the interface under pressure at low sliding speed. The sliding body is lifted by
this permanent lubricant layer. Such slideways are called as hydrostatic slideways.

Guideways with Rolling Friction

These are also called as anti friction ways. The anti friction slideways may be classified
according to the shape of the rolling element as:
(a) Roller type anti friction ways using cylindrical rollers.
(b) Ball type anti friction ways using spherical balls.

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Shapes of slideways

(a) (b)

(c)

(d) (e)

Slideways profiles: (a) Flat; (b) Symmetrical V; (c) Asymmetrical V; (d) dovetail
(e) Cylindrical

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EXPERIMENT NO.13
Object: Commonly used bed section and wall arrangement and their applications.
Wall Arrangement Applications
1.) Beds on logs or sheas
a.) without stiffening, diagonal wall, used
in lathe, turrets, etc.
b.) without stiffening diagonal wall has 30-
40% height stiffness than arrangement (a);
used in multiple tool and height production
lathes.
(a) (b)
c.) with stiffening wall and provision of
chip disposal through opening in rear wall,
used in large sized lathes & turret with
stiffing wall, also used in large-sized laths.
(d) With stiffening wall also used in large
size lathe and turret

(c) (d)

2.) Covered top closed profile bed, used in

plan milling, clothing & boring machines.

3.) Open top closed profile bed, used when

the bed is also require, commonly
employed in grinding machine.

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Experiments:9
Objective: - Design a four / six speed Gear Box.
Introduction: - A Gearbox is a mechanical device that is used to provide Speed and Torque
conversions from a rotating power source to output shaft. As the speed of the shaft increases, the
torque transmitted decreases and vice versa. Multi-speed gearboxes are used in applications which
require frequent changes to the speed/torque at the output shaft. Gearboxes work on the principle
of meshing of teeth, which result in the transmission of motion and power from the input source to
the output.

A gearbox is formed by mounting different gears in appropriate speed ratios to obtain the desired
variations in speed. Gearboxes usually have multiple sets of gears that are placed appropriately to
obtain different speed reductions. The types of gearboxes are Sliding mesh gearbox, Constant mesh
gearbox, synchromesh gearbox. In a sliding mesh gearbox, the two types of gears are sliding gears
and stationary gears. The sliding gears are mounted on splined shafts to enable them to slide along
the axis of the shaft to enable meshing with different pairs of gear.

GENERAL CONCEPT OF A GEARBOX

The main purpose of a gearbox is to transmit power according to variable needs from an input
power source to the desired output member. A Gearbox is a mechanical device that is used to
provide Speed and Torque conversions from a rotating power source to output shaft. As the speed
of the shaft increases, the torque transmitted decreases and vice versa. Multi-speed gearboxes are
used in applications which require frequent changes to the speed/torque at the output shaft.
Gearboxes work on the principle of meshing of teeth, which result in the transmission of motion and
power from the input source to the output.

USES OF A GEARBOX:

Gearboxes are used for some or all of the following purposes,

Changing the Direction through which the power is transmitted.

Changing the amount of force or torque that is transmitted.
Changing the Revolutionary speed of the input relative to the output.

LIST OF COMPONENTS USED IN A GEARBOX:

Some of the primary components used in a Gearbox are listed below.

Gears
Bearings
Shafts

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TYPES OF GEARING

The following are the primary types of gearing in a Gearbox. These may be used individually or in
unison with other types

Spur Gearing
Helical Gearing
Herringbone Gearing
Epicyclic or Planetary Gearing.

TERMS ASSOCIATED WITH A GEARBOX

The following are some of the terms associated with gearboxes and their working

Gear Ratio
Power Transmitted
Type of Drive
Step Ratio
Number of Speeds

SPUR GEARS

Spur gears are gears which have vertical upright teeth perpendicular to the radial axis of the Gear
wheel. The following figure illustrates the terms and notations associated with a spur gear.

Fig. Spur Gear

Spur Gears are used to transmit power and motion between parallel axes or shafts. The gear types
available for spur gear vary in terms of their module, metric gears, pinion gears, racks, internal and

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cluster gears etc. The Gears mesh or mate with teeth of very specific geometry. If the teeth are not
cut to the required level of accuracy, the teeth may interfere with each others movements and
cause jamming or locking.

SOME TERMS ASSOCIATED WITH SPUR GEARS

MODULE

Module is the ratio of pitch circle diameter in mm to the number of teeth in the same gear.

PITCH

Pitch is a measure of the tooth spacing and is expressed in several ways.

1. Circular Pitch pc : It is a direct measure of the distance from one tooth center to the adjacent
tooth center. It is one of the most widely used terms in gearing.
2. Diameter Pitch pd : The ratio of number of teeth to the pitch circle diameter in inches is
called the diameter pitch.

PRESSURE ANGLE

The angle between the line of force between meshing teeth and the tangent to the pitch circle at the
point of mesh is the pressure angle.

Gears must have the same module and pressure angle to mesh without interference.

DESIGN AND ASSOCIATED CALCULATIONS

There are many ways of approaching the design of a multi speed gearbox. One of the methods is to
consider each pair individually and design them accordingly and check if they meet the required
design and operating criteria. This method of design is called the Lewis Buckingham method and the
gears subjected to the highest loads/stresses/forces are designed since all the remaining gears,
designed proportionally will satisfy the required safe operation criterion.

INITIAL SPECIFICATIONS FOR THE GEARBOX

Power transmitted: 2KW

Max. Speed: 1400 rpm
Min. Speed: 460 rpm

CALCULATION OF PROGRESSION RATIO

nmax / nmin = 1400/460 = 6-1

= 1.249

We take 1.12 * 1.12 = 1.254 (Skipping one Speed)

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Department of Mechanical Engineering, RTU